System for fabricating a fuel cell component for use with or as part of a fuel cell in a fuel cell stack

ABSTRACT

A system for fabricating a fuel cell component in which a deposition mechanism deposits loading material particles onto the fuel cell component and an actuation mechanism actuates the deposition mechanism. A unit provides a tape fixing agent to the fuel cell component and loaded material particles so as to retain the particles on the fuel cell component. Other fuel components are retained to the fuel cell component also using a tape fixing agent.

BACKGROUND OF THE INVENTION

This invention relates to fuel cells and, in particular, to fuel cellassemblies and components having loaded and retained catalyst thereinand to apparatus and methods for performing such loading and retaining.

A fuel cell is a device which directly converts chemical energy storedin hydrocarbon fuel into electrical energy by means of anelectrochemical reaction. Generally, a fuel cell comprises an anode anda cathode separated by an electrolyte, which serves to conductelectrically charged ions. In order to produce a useful power level, anumber of individual fuel cells are stacked in series with anelectrically conductive separator plate between each cell.

In internally reforming fuel cells, a reforming catalyst is placedwithin the fuel cell stack to allow direct use of hydrocarbon fuels suchas methane, coal gas, etc. without the need for expensive and complexreforming equipment. In a reforming reaction, fuel cell produced waterand heat are used by the reforming reaction, and the hydrocarbon fuel isinternally reformed to produce hydrogen for fuel cell use. Thus, thenecessary hydrogen fuel is produced by the reforming reaction, and sincethe reaction is endothermic, it can also be used advantageously to helpcool the fuel cell stack.

Two different types of internal reforming have been developed for fuelcell assemblies. One type of internal reforming is indirect internalreforming, which is accomplished by placing the reforming catalyst in anisolated chamber within the stack and routing the reformed gas from thischamber into the anode compartment of the fuel cell. A second type ofinternal reforming is direct internal reforming. This type of internalreforming is accomplished by placing the reforming catalyst within theactive anode compartment or fuel flow field, which provides the hydrogenproduced by the reforming reaction directly to the anode.

A typical fuel cell anode compartment comprises a separator or bipolarplate for isolating fuel from the oxidant stream of the neighboring fuelcell, an anode electrode for providing electrochemical reaction sites,and an anode current collector often provided as a corrugated plate, forconducting electronic current from the anode electrode. The anodecurrent collector is in contact with the anode electrode and alsodefines flow channels for the fuel gas. The reforming catalyst is placedin these flow channels to provide the direct internal reforming.

The reforming catalyst is usually available as compacted or solidparticles having various solid shapes or forms such as tablet, pellet,rod, ring or sphere. However, due to the dimensions of the catalystparticles, difficulties have been encountered in trying to load theparticles in the current collector channels. One difficulty is that therelatively small size of the catalyst particles makes them difficult tohandle during assembly. This, in turn, makes the process of catalystloading inefficient, and thus, unduly costly.

A second difficulty sometimes arises in achieving and maintaining adesired loading pattern of the catalyst because of the tendency of thecatalyst particles to shift during the loading process and the fuel cellassembly process. The importance of the desired loading pattern stems inpart from the desire to maintain a required heating profile in the fuelcell stack. This profile helps promote efficient and long term operationof the stack.

A manner of improving the efficiency and reliability of loading thecatalyst particles in fuel cell components is thus always desirable.Additionally, the ability to better retain the loaded catalyst whileconcurrently enabling maximum operational efficiency is also a goal inthe manufacturing process.

SUMMARY OF THE INVENTION

In accordance with the embodiment(s) of the invention disclosedhereinafter, an apparatus and associated method are provided in a systemfor accurately loading catalyst particles into fuel cell components. Anapparatus and associated method are also provided in a system which usesa fixing agent for retaining the loaded catalyst and, if desired, otherfuel cell components.

A particular system in use of the apparatus and method comprises asupport for supporting a fuel cell component adapted to receive catalystparticles and a deposition assembly adapted to load the catalystparticles onto the fuel cell component. The system further optionallycomprises a mechanism for applying a fixing agent to the fuel cellcomponent and the loaded catalyst particles for retention of thecatalyst particles.

In a further aspect of the invention, the fixing agent applied to thefuel cell component is further adapted to permit the fuel cell componentto be held to another fuel component. It is also contemplated that alike fixing agent be used with additional fuel cell components so thatthese additional components, the another component and the catalystloaded component, with the aid of the fixing agent, are held together soas to in facilitate handling and stacking of the components in theformation of a fuel cell stack.

In the embodiments disclosed, the fuel cell component is a corrugatedanode current collector, the other component is a separator plate andthe additional components are an anode, a cathode and a cathode currentcollector and the fixing agent is a double-sided adhesive medium.

It is contemplated that the aforementioned fixing agent comprises,optionally, a double-sided acrylic adhesive tape of the type currentlymanufactured by the 3M Company.

In one illustrative form of the invention, the deposition assemblyincludes individual deposition mechanisms each adapted to urge acatalyst particle delivered to the deposition mechanism onto the fuelcell component. The deposition mechanisms are arranged in a row acrossthe width of the fuel cell component and are caused to be selectivelyoperated based on the sensed position of the fuel cell component. As thefuel cell component is indexed, the sensed position causes an actuatorassembly to selectively operate the deposition mechanisms and thiscontinues until the fuel cell component is loaded. In this embodiment,each deposition mechanism optionally comprises a hydraulic or pneumaticcylinder or an electric actuator with a plunger and a gate assembly. Thegate assembly holds the catalyst particle and prevents it from beingdelivered to the fuel cell component. Upon operation of the actuatorassembly, the gate assembly is released and the hydraulic or pneumaticcylinder or electric actuator moves the plunger to urge the catalystparticle onto the fuel cell component.

In another illustrative embodiment, the deposition assembly includes amask gate assembly having overlying first and second plates. The firstplate has openings corresponding to the predetermined areas on the fuelcell component to receive catalyst and the second plate has openingscorresponding to all the areas of the fuel cell component able toreceive catalyst particles. The first plate is disposed over the fuelcell component and the second plate is disposed over the first plate sothat its openings are misaligned with the openings of the first plate.The second plate is then loaded with catalyst particles which come toreside in the plate openings and are blocked from entering the openingsin the first plate due to the misalignment.

The second plate is then shifted by the actuator assembly so that itsopenings then align with those in the first plate. Vibration motionbeing applied to the plates causes the catalysts in the aligned openingsof the two plates to pass from the openings in the second plate throughthe aligned openings of the first plate and from these openings to thecorresponding areas of the fuel cell component. The fuel component isthereby loaded with a predetermined pattern of catalyst defined by thefirst plate.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and aspects of the present invention willbecome more apparent upon reading the following detailed description inconjunction with the accompanying drawings, in which:

FIG. 1 shows a molten carbonate fuel cell with a first reformingcatalyst member.

FIG. 1A shows a molten carbonate fuel cell with a second reformingcatalyst member.

FIG. 2 shows a system for the placement of catalyst particles in theform of pellets onto a current collector associated with the anodeelectrode of a fuel cell assembly.

FIG. 3 shows the system of FIG. 2 and subsequent placement of a fixingagent to retain positioning of the loaded catalyst particles relative tothe current collector

FIGS. 3A-3C show the details of the deposition mechanisms of the systemof FIGS. 2 and 3 and the sequence of operation of these mechanisms.

FIG. 4 shows final placement of the catalyst members in a chosen patternrelative to the current collector.

FIG. 4A shows the second catalyst member as shown in FIG. 1A.

FIG. 5 shows, demonstrably, the process of using a fixing agent inadhering a current collector loaded with the catalyst particles to othercomponents in the forming of a fuel cell assembly.

FIG. 6 shows an exploded view of the components of a fuel cell assemblyjoined together with a fixing agent.

FIG. 7 shows a vacuum press unit for compressing under heat the fuelcell assembly of FIG. 6.

FIG. 8 shows a further system for the placement of catalyst particles inthe form of pellets onto a current collector.

FIG. 9 shows the mask gate assembly of the system of FIG. 8.

FIGS. 10 and 11 show an exploded view of a portion of the mask gateassembly of FIG. 9 with the mask gate closed and opened, respectively

DETAILED DESCRIPTION

Referring to FIGS. 1, 1A and 6, there is shown a fuel cell stack formedby stacking assemblies 10 one on the other with an electrolyte matrix 11between adjacent assemblies. The electrolyte matrix 11 is adapted holdan electrolyte such as, for example, a carbonate electrolyte. Eachassembly 10 comprises an anode electrode 12 and an associated currentcollector 14, shown as having corrugations 14A. Each assembly 10 furthercomprises a bipolar separator 16 which separates the anode electrode 12and current collector 14 from a cathode electrode 18 and its associatedcurrent collector 20, also shown as having corrugations 20A. Thecorrugations 14A of the anode current collector 14 define with thebipolar separator plate 16 and the anode electrode 12, first and secondsets of fuel gas channels 14B and 14C. The anode current collector isfurther loaded with a plurality of catalyst particles 22 situated in thechannels 14B and, in particular, in the areas 14D between and engaged bythe legs of adjacent corrugations 14A. The catalyst particles 22 cantake on various configurations. In FIG. 1, the catalyst particles 22 areshown as having a square cross-section and in FIG. 2 as having acircular cross-section. Other cross-section shapes such as hexagonal and“star” to improve the available surface area can also be used for thecatalyst particles 22.

The catalyst particles 22 promote further reforming of the hydrocarbonsin the fuel gas in the channels 14B to increase the hydrogen content ofthe gas. A portion of the further reformed gas in the channels 14B thenpasses into the channels 14C via openings in or discontinuities in thecorrugations 14A as the gas continues traveling along the channels 14B.The further reformed gas thus combines with the fuel gas introduceddirectly into the channels 14C and the combined gas is thereby madeavailable to participate in the electrochemical conversion reaction atthe anode 12.

In order that the above-mentioned reforming reaction takes placeefficiently in the fuel gas channels 14B and also in order to promote adesired heating profile for the fuel cell stack, it is desirable to loadthe anode current collector 14 with the catalyst particles 22 in acertain pattern and to retain that pattern. Accordingly, the followingprovides an advantageous way in which to achieve both the loading andretaining of the catalyst particles in a desired pattern.

Referring to FIGS. 2-3, there is shown schematically a system 24 for theloading and retaining of the catalyst particles 22 on the anode currentcollector 14. The catalyst particles 22, optionally provided in the formof pellets as shown in FIG. 2, are fed from a hopper 26 situated in thevicinity of the current collector 14. The current collector 14 rests onan X-Y movable support or table 51 capable of moving in the X and Ydirections. Looking at FIGS. 2 and 3, the hopper 26 is provided with ahopper feed 28 containing a plurality of feed channels 28A arranged in arow so as to span the width (X direction) of the current collector 14.The feed channels 28A lead to a deposition assembly 29 comprised of arow or line of deposition mechanisms 30 also situated to span the widthof the current collector 14.

Each of the deposition mechanisms 30 is fed by one of the feed channels28A and is further aligned with one of the areas 14D between adjacentlegs of the corrugations 14A spanning the width of the currentcollector. By selecting the number of deposition mechanisms 30 to beequal to the number of spaces 14D, each space 14D across the width ofthe collector plate 14 is able to be fed a catalyst particle 22 by itsrespective deposition mechanism. Moreover, as shown in FIG. 3 and asabove-mentioned, the corrugations 14A are discontinuous in the lengthdirection (Y direction) of the current collector so that they form aplurality of spaced rows 36. Accordingly by bringing each row 36 ofcorrugations in line with the row of deposition mechanisms 30, thespaces 14D in each row are able to be fed catalyst particles 22 by theassociated deposition mechanisms 30.

More particularly, the hopper 26, as a result of vibratory motionimparted thereto, delivers a catalyst particle 22 to each of the feedchannels 28A of the hopper feed 28. Each feed channel, in turn, brings acatalyst particle 22 to its respective deposition mechanism 30. In thecase shown, as can be seen in more detail in FIGS. 3A-3C, eachdeposition mechanism 30 defines a chamber 30A in which the fed catalystparticle 22 settles and is held by a gate assembly shown optionally as aspring loaded ball assembly 30B. Other forms of the gate assembly mightbe an actuator or cylinder assembly. Above the gate assembly, thedeposition mechanism 30 includes a hydraulic or pneumatic cylinder orelectric actuator 30C equipped with a plunger 35 which contacts thecatalyst particle.

Actuation of a deposition mechanism 30 then results in the sequence ofoperations in FIGS. 3A-3C. The assembly 30B is first retracted allowingthe passage of the catalyst particle 22 downward through the chamber30A. The hydraulic or pneumatic cylinder or electric actuator 30C thenoperates causing its plunger to force the catalyst particle 22 downwardinto the area 14D between the feet of the adjacent corrugations 14. Atthis time, the plunger also blocks entry of further catalyst particles22 into the chamber. This blockage can also be accomplished by a clampbar or similar type of assembly that is brought into the path of thefurther catalyst particles in conjunction with the plunger being moveddownward. The hydraulic or pneumatic cylinder or electric actuatorcylinder 30C then completes its stroke forcing the catalyst particle 22to be held between the corrugations.

Once this operation completes, the hydraulic or pneumatic cylinder orelectric actuator 30C retracts the plunger and the spring loaded ballassembly 30B returns to its original position. This allows the nextcatalyst particle 22 from the feed chamber 28A to be delivered to andheld in the chamber 30A of the deposition mechanism 30 for subsequentsupply to the current collector 14.

Whether a particular deposition mechanism 30 in the deposition assemblyis actuated is determined by an actuating assembly in the form of aprogrammed controller 38. The controller also controls the operation ofthe other components of the system 24 including the X-Y table or support51.

Indexing of the table 51 under the control of the programmed controller38 successively brings each of the rows 36 of corrugations 14A into linewith the row of deposition mechanisms 30 which in the present caseremain stationary. A sensor 40 acts as to indicate to the programmedcontroller 38 that a row 36 of corrugations 32 (see, FIG. 4) has nowbeen brought into line with the row of mechanisms 30 of the depositionassembly 29. A simple counting mechanism in the controller, counts therows, so that the programmed controller can identify a particular row.The controller 38 then based on a predetermined stored catalyst patternwhich correlates row numbers and associated areas 14D to receivecatalyst particles 22, actuates the particular depositions mechanisms 30associated with the catalyst receiving areas. This results in depositionof catalyst particles 22 by the mechanisms 30 in the particular row inaccordance with the predetermined pattern.

Continued indexing of the table 51 in the Y direction and actuation ofthe deposition mechanisms 30 by the controller 38 thus results in thedeposition of the catalysts particles 22 into all the rows of thecorrugations of the collector 14 in accordance with the predeterminedcatalyst pattern. It is to be understood that the controller 38 can beprogrammed to obtain any desired predetermined pattern or to change thepredetermined pattern for the catalyst deposition. Accordingly, thedeposition of catalyst particles in the current collector 14 can be madeso as to achieve a predetermined pattern for heat management throughoutthe fuel cell stack to realize a maximum energy yield.

With continued reference to FIGS. 2-3, there is also provided in thesystem 24, a fixing agent 42 for retaining the placement of each of thecatalyst particles 22 within their respective areas 14D of thecorrugations 14A. The fixing agent 42 is carried on a supply roller 61and is, optionally, in the form of a dual-sided medium comprising doublesided acrylic tape. The tape comprises an exposed adhesive side 43 and acovered adhesive side 45 protected by a backing 47 (see, FIG. 5).

In use, once the catalyst particles 22 are in position, application ofthe tape 42 on the supply roller 61 occurs by use of the press roller 62which guides and presses the tape 42 on the catalyst members 22 andcorrugations 14A in a manner well understood by one of ordinary skill inthe art. Such application enables sealing of the catalyst particles 22against the respective legs of the corrugations 14A of the collector 14.This occurs, as will be understood by one of ordinary skill in the art,since the side 43 is urged against the catalyst particles andcorrugations 14A by the press roller 62 while the side 47 is free fromcontact therewith.

As shown in FIG. 3 by the cutout portion thereof, the resultantplacement of the catalyst particles 22 is retained, as is represented byFIG. 4. It is to be understood that the fixing agent of the presentinvention may also be arranged for use with an alternatively shapedcatalyst member 46, optionally provided as an extruded materialdimensioned substantially cylindrically, as shown in FIG. 4A. With theoption of using an alternative member 46 such as that shown andcorresponding to member 23 of FIG. 1A, any one such member 46 may beprovided in a dimension extending substantially the length of thecollector plate 14.

With reference to FIGS. 5-6, the process of assembling the fuel cellassembly 10 using the fixing agent 42 is described. Once application ofthe adhesive side 43 of the tape 42 occurs such that the uncoveredadhesive attaches atop the catalyst particles 22 and portions of thecollector plate 14, the backing 47 covering the opposed side 45 of thetape 42 is available for removal therefrom. This removal is shown asindicated by arrow “A” in FIG. 5.

Referring to FIGS. 6, 1 and 1A, there is shown, diagrammatically, theassembly shown in FIGS. 1 and 1A. Such assembly comprises the use of thefixing agent 42 not only in retention of the catalyst particles 22 tothe collector plate 14, but also in retention of the electrodes 12 and18 and their associated collector plates 14 and 20 to the bipolarseparator plate 16. As such, it may be seen that the anode electrode 12is assembled to its respective current collector plate 14 by strips ofthe tape 42 described hereinabove and situated on the top side of theplate. The underside 48 of the collector plate 14 housing the catalystmembers 22 is covered with the exposed adhesive side 43 of the tape 42.The backing 47, as shown in FIG. 5, is then removed to enable adherenceto, and thus construction with, the bipolar separator plate 16.Accordingly, the anode half of the fuel cell assembly 10 is thenachieved.

Construction of the cathode half of the fuel cell assembly 10 begins byattaching the underside 54 of the cathode current collector 20 to theunderside 56 of the bipolar separator plate 16 via the tape strips 42 onthe underside of the bipolar plate after removal of the backing 47 ofthese strips exposing the adhesive layer 43. Thereafter, with theexposed adhesive side 43 of the tape 42 covering the surface 58 of thecathode current collector 20, the backing 47 thereof is ready to beremoved. Once removed, the cathode electrode 18 may be adhered theretoto complete assembly of the cathode half of the fuel cell assembly 10.

In order to ensure that the components of the assembly 10 remain intact, the assembly 10 can be subjected to pressure and heat in order toenhance the retention power of the tape 42. FIG. 7 shows a vacuum pressunit 71 which can be used of this purpose. The unit 71 includes upperand lower platens 72 and 73 supported, respectively, on a top cover 74pivotably attached to a base assembly 75. The top cover 74 carries avacuum sealing gasket 76 which borders the periphery of the upper platen72. When the cover 74 is lowered by pivoting, the upper and lowerplatens 72 and 73 are brought together by locating pins 77 on the baseassembly 75 and corresponding locating holes 78 in the cover to form asealed vacuum chamber for receiving the assembled fuel cell assembly 10.

A heated air inflow unit 79 is then turned on to draw-in outside air andto heat the air. The heated air is then delivered to the sealed vacuumchamber through a plenum along the side 75A of the base assembly. Airdelivery ports 81 convey the heated air from the plenum to the sealedvacuum chamber between the platens when the platens are brought togetherwith the assembly 10 secured between them.

The heated air heats the assembly 10 and passes from the vacuum chambervia air exit ports 82 on the other side 75B of the base assembly 75 to aplenum on this side of the assembly. After assembly 10 reaches a desiredtemperature, the heated air unit 79 closes or shuts off and a blower orfan 83 is turned on. This allows the blower or fan 83 to draw vacuumfrom the base assembly 75 with the assembly 10 in it via the air exitports 82 and the plenum on the side 75B of the base assembly 75. As aresult, a thermo-vacuum pressing of the assembly 10 is carried out.After a predetermined time, the pressing of the assembly 10 is completeand the fan 83 is turned off. The platens 72 and 73 are then separatedby pivoting the top cover 74 upward, thereby allowing removal of theassembly 10.

FIGS. 8-11 show a further assembly for deposition of the catalystparticles into preselected of the areas 14D of the current collector 14.As shown the system comprises a mass block or base member 91 whichsupports a vibratory block 92. A mask gate assembly 93 is supported bythe vibratory block 92 against the anode current collector 14 which isto be loaded with catalyst particles. A hopper 94 holds catalystparticles in the form of pellets and these are fed to the mask gateassembly 93.

The mask gate assembly is shown in more detail in FIGS. 9-11 andcomprises clamp bars 93C, 93D and pneumatic clamps 93E which clampoverlying gate and mask plates 93A and 93B together and to the vibratoryblock over the current collector 14. As shown, the mask plate 93B liesabove the gate plate 93A and the gate plate 93A faces the currentcollector. Spring loaded pins 93F provide a downward force across thesurface of the mask plate 93B, while still permitting catalyst pelletsto have access to the openings in the mask plate as discussed furtherhereinbelow. The clamping of the plates is such that the gate plate 93Acan be shifted or translated laterally (in the direction of the arrow B)relative to the mask plate 93B via a mechanical force applied by anoperator either directly or via an actuator.

The mask plate 93B has through openings equal in number and positionedto coincide with the pre-selected areas 14D between the legs or feet ofadjacent corrugations of the collector which are to receive catalystpellets in accordance with the desired pattern. The gate plate 93A, inturn, also has through openings. These openings, however, are equal innumber and positioned to coincide with all the areas 14D of thecollector.

As shown in FIG. 10, the mask gate assembly 93 is clamped to thevibratory block 92 over the current collector so that the throughopenings in the gate plate 93A are misaligned with the areas 14D of thecurrent collector while the through openings of the mask plate 93B arealigned with these openings. Solid areas of the gate plate 93A thusblock movement from the through openings of the mask plate 93B to theareas 14D of the current collector. In this closed position of the gateassembly 93, vibration is used to move catalyst pellets from the hopper94 so that they distribute along the length of the mask plate 93B anddeposit in the through openings of the mask plate.

The mask plate 93B is designed such that only one catalyst pellet canreside in each of its openings. The catalyst pellets also cannot sit ontop of one another due to the mask plate thickness being less than thepellet diameter. This creates channels for the catalyst pellets totravel along until they reach an empty opening in the mask plate. Oncethe openings in the mask plate 93B are all filled, the gate plate 93A isshifted laterally as shown by the arrow B in FIG. 10 to bring the maskgate assembly 93 to its open position as shown in FIG. 11.

In this position, due to the shifting of the gate plate 93A, the throughopenings in the gate plate now align with the areas 14D of the currentcollector and also with the through openings in the mask plate 93B. Thecatalyst pellets thus fall in the direction of the arrow C from theopenings in the mask plate 93B through the corresponding openings in thegate plate 93A into the underlying areas 14D of the current collector.The current collector 14 thus becomes loaded with catalyst pellets inaccordance with the desired predetermined pattern.

Moreover, the vibratory motion imparted to the current collector by theblock 92 causes the catalyst pellets to orient themselves in the areasor pockets 14D of the current collector in such a way as to not protrudeabove the height of the legs defining the areas. This allows for furtherprocessing of the catalyst loaded current collector as by application ofan adhesive fixing agent to hold the catalyst pellets in the currentcollector as discussed above.

To aid in securing the catalyst pellets in the areas 14D of the currentcollector, the vibratory block 92 is adapted to be subjected to a vacuumwhich secures the current collector to the block via an adhesivemembrane on the current collector. This provides an intimate contactbetween the collector and a very smooth, even transmission of vibration.As a result, the catalyst pellets are moved into and settle into theareas 14D so as to not protrude from the current collector asabove-described.

In all cases it is to be understood that the above-described subjectmatter is merely illustrative of the many possible specific embodiments,which represent applications of the present invention. Numerous andvaried other arrangements can be readily devised in accordance with theprinciples of the present invention, without departing from the spiritand scope of the invention. In particular, while the invention has beenillustrated in terms of loading an anode current collector with catalystparticles, it is evident that the principles of the invention extend toloading of other fuel cell components defining or forming the anode flowfield or fuel flow field of a fuel cell. Loading of a bipolar separatorplate with catalyst particles might be one example.

What is claimed is:
 1. A system of fabricating a fuel cell component foruse with or as part of a fuel cell in a fuel cell stack, the systemcomprising: a support supporting the fuel cell component, said fuel cellcomponent including a plurality of corrugations; a deposition assemblyfor depositing individually pre-formed solid loading material pelletsonto the fuel cell component in a pre-defined deposition pattern; anactuating assembly for actuating the deposition assembly to cause saiddeposition assembly to deposit said individually pre-formed solidloading material pellets onto said fuel cell component; and a feedingassembly housing a plurality of individually pre-formed solid loadingmaterial pellets and feeding the individually pre-formed solid loadingmaterial pellets individually to the deposition assembly, wherein thedeposition assembly places each individually pre-formed solid loadingmaterial pellet individually into an area between adjacent corrugationsof the fuel cell component in accordance with the pre-defined depositionpattern.
 2. The system in accordance with claim 1, further comprising: aunit moving one or more of the support and the deposition assembly tocause movement of the fuel cell component and the deposition assemblyrelative to one another; and a sensing unit locating the position ofsaid fuel cell component; and wherein said actuating assembly isresponsive to said sensing unit.
 3. The system in accordance with claim2, wherein: the deposition assembly includes a plurality of depositionmechanisms arranged in a row to span a first dimension of the fuel cellcomponent, each deposition mechanism depositing an individuallypreformed solid loading material pellet individually onto the fuel cellcomponent when actuated; and said actuating mechanism actuates saiddeposition mechanisms in accordance with the pre-defined depositionpattern.
 4. The system in accordance with claim 3, wherein: eachdeposition mechanism includes: one of a hydraulic or pneumatic cylinderor electric actuator with a plunger; and a gate assembly for selectivelyallowing passage onto said fuel cell component.
 5. The system inaccordance with claim 1, wherein: said pre-defined deposition pattern isassociated with a desired heating profile of the fuel cell stack.
 6. Thesystem in accordance with claim 1, further comprising: a unit applying afixing agent relative to the fuel cell component and to the loadingmaterial to maintain positioning of the loading material relative to thefuel cell component.
 7. The system in accordance with claim 6, wherein:said fixing agent is an adhesive tape.
 8. The system in accordance withclaim 7, wherein: said adhesive tape is a double-sided adhesive tape. 9.The system in accordance with claim 8, further comprising: a unit forapplying heat and pressure to said fuel cell component and said fixingagent.
 10. The system in accordance with claim 1, wherein: saidindividually pre-formed solid loading material pellets comprise catalystpellets.
 11. The system in accordance with claim 1, wherein the fuelcell component comprises a plurality of rows defined by saidcorrugations, each row including areas for receiving loading materialparticles; and the deposition assembly includes a plurality ofdeposition mechanisms, each deposition mechanism associated with an areaof the areas in a row; and each deposition mechanism is actuatedaccording to the pre-defined deposition pattern.
 12. The system inaccordance with claim 11, wherein: the pre-defined deposition pattern isassociated with a desired heating profile of the fuel cell stack. 13.The system in accordance with claim 1, wherein: said fuel cell componentincludes one or more of an anode current collector, a component used informing the fuel flow field of a fuel cell and a component used informing the anode flow field of a fuel cell.
 14. The system inaccordance with claim 1, wherein: said fuel cell component is one ormore of an anode, an anode current collector, a bipolar separator, acathode and a cathode current collector.
 15. A system of fabricating afuel cell component for use with or as part of a fuel cell in a fuelcell stack in accordance with claim 1, wherein: said support comprises abase member; said actuating assembly comprises a vibratory blocksupported on the base member and adapted to support the fuel cellcomponent; and said deposition assembly comprises a mask gate assemblyattached to the vibratory block above the fuel cell component, said maskgate assembly including: a gate plate having openings corresponding tothe areas of said fuel cell component able to receive solid loadingmaterial pellets; and a mask plate situated above said gate plate andhaving openings corresponding to said pre-defined deposition pattern,said gate and mask plate being arranged to be translatable relative toone another so that said mask and gate plates become mis-aligned so thatthe openings in said mask plate are misaligned with the openings in saidgate plate and the loading material pellets in the openings of said maskplate are inhibited from passing through the openings in said gate plateand so that said mask and gate plates become aligned so that theopenings in said mask plate align with the openings in said gate plateand loading material pellets pass from said openings in said mask plateto the aligned openings in said gate plate to deposit on said fuel cellcomponent in said pre-defined deposition pattern.
 16. A system inaccordance with claim 15, wherein: vibration of said vibratory blockcauses said loading material particles to pass onto said mask plate andinto the openings of said mask plate and aids the loading pellets topass through the openings in said mask plate into and through theopenings of said gate plate to settle on said fuel cell component.
 17. Asystem in accordance with claim 16, wherein: said vibratory block isadapted to be subjected to a vacuum to hold said fuel cell component tosaid vibratory block.
 18. A system in accordance with claim 16, whereinsaid gate plate is movable relative to mask plate.
 19. A system inaccordance with claim 16, wherein: said mask gate assembly includesclamps for clamping said mask gate assembly to said vibratory block. 20.A system in accordance with claim 16, wherein: said fuel cell componentis one or more of an anode current collector, a component used informing the fuel flow field of a fuel cell and a component used informing the anode flow field of a fuel cell; and said loading materialis a catalyst.
 21. A system in accordance with claim 15, wherein: saidfuel cell component is one or more of an anode current collector, acomponent used in forming the fuel flow field of a fuel cell and acomponent used in forming the anode flow field of a fuel cell; and saidloading material is a catalyst.
 22. A system in accordance with claim 1,wherein said deposition assembly deposits said individually pre-formedsolid material pellets into predetermined areas between adjacentcorrugations of the fuel cell component so as to deposit a plurality ofsaid individually pre-formed solid material pellets into each saidpredetermined area in predetermined positions along each saidpredetermined area in accordance with the pre-defined depositionpattern.
 23. A system of fabricating a fuel cell component for use withor as part of a fuel cell in a fuel cell stack, the system comprising: asupport supporting the fuel cell component, said fuel cell componentincluding a plurality of corrugations; a deposition assembly fordepositing individually pre-formed solid loading material pellets ontothe fuel cell component in a pre-defined deposition pattern, saiddeposition assembly including a first plate having openingscorresponding to the areas of said fuel cell component able to receiveindividually pre-formed loading material pellets and a second platesituated above said first plate and having openings corresponding tosaid pre-defined deposition pattern, said plates being mis-aligned sothat individually pre-formed loading material pellets in the openings ofsaid second plate are inhibited from passing through the openings insaid first plate for deposition on said fuel cell component; and anactuating assembly for actuating the deposition assembly to cause saiddeposition assembly to deposit said individually pre-formed solidloading material pellets onto said fuel cell component, said actuatingassembly causing relative movement of said first and second plates sothat the openings in said second plate align with the openings in saidfirst plate and loading material pellets pass from said openings in saidsecond plate to the aligned openings in said first plate to deposit onsaid fuel cell component, wherein the deposition assembly places eachindividually pre-formed solid loading material pellet individually intoan area between adjacent corrugations of the fuel cell component inaccordance with the pre-defined deposition pattern.
 24. A system inaccordance with claim 23, wherein each of the openings of said secondplate is configured to receive one individually pre-formed solid loadingmaterial pellet.